When installing RAVE Valves it is necessary to plug the openings of the cylinders where the OEM valve shaft goes thru. The installation kit includes a plug. The cylinders need to be drilled and tap to accepst the plug and then silicone should go over it. I choosed to seal it with JB Weld. This way I can remove it later if I decide to sell the cylinders or convert back





Clean the surface with acetone, tape the bottom and top. Cut wht opening with a utility blade.



Mix JB-Weld on the end of a hefty zip lock bag and cut the tip of it.





Follows your Grandma's cake icing technique
Fill the smaller opening first then the rest all the way to the top. Take an utility blade and runit on the outer area of the opening to smothen it and remove any excess.





Let it cure and remove the tapes.

Then do the other side

Reserved

Have the issues with bellows type, spring type/tension and caps (with stock exh)height been improved? Or is it much the same game?

Ok - now just how is JB Weld easier to remove than silicone? Inquiring minds want to know!

Jay with the provided kit you are supposed to drill and tap (irreversible mod) plug and then add silicone.

For what I understand you can heat up the cylinder with a torch and the JB weld will come off.

GPRVET. Same issues. I have just mastered this valves. The black bellows work great with single pipes and green bellows for triples. I also use the red Doo springs and long zip ties instead of loop springs to hold the bellows against the caps.

[ 03-28-2003, 10:08 PM: Message edited by: Fercho ]

Make note: paint repair silver to match cylinder so it doesn't look like crap

As usual, an excellent example from Fercho.

I used the bolt plug kit from Carl at Island Racing. Works fine and is easy to install with the cyls in place.

Gary

would someone be able to install gas valves without removing the cylinders? Does JB Weld hold up well? Could I add that to the shaft holes w/o removing the cylinders?

John

99XL1200R
My Setup

John,
As I have been told, you are going to run into one big problem, along with the obvious problem of getting the stuff out of the holes, and closing them up.

The stock pipe needs to be trimmed back, just a tad, to make it fit. I think this is shown on Brians page here...
http://www.wppracing.com/Technical%20Modifications.htm

It's definately not a slam dunk project, but the results are pretty nice! The valves are always in the right place, at the right time, with little chance of dropping a valve.

mark c
http://www.hydrotoys.com
02 GP1200R
96 XP
01 FZ-1
00 Sportsman 500
02 Bombbardier DS650 Baja
04 SXR 800

Well, on a better note, i will be going Triples, so I don't really have to worry about the exhaust. So it might be easier to just pull the jugs, huh?

How is the JB Weld holding up?

John

99XL1200R
My Setup

1/8 npt tap and plug it. $5 in parts at ace hardware. jb weld will not last, in time engine harmonics will soften the bond and it will fail. making a mess of ur pretty engine compartment. once u go gas ull never look back.

my speedwerx cylinders have a plug pressed in where the old seal was installed. if u dont want to tap, call werx and see if they will sell you just the plug. u may ba able to match the size up at a auto parts store, ie., auto freeze out plugs...rather small opening i know, so i doubt it, but then again, im sure werx just found the part for another use and retrofitted it.

What I did to preserve the holes, yet prevent failure was use allen head bolt, and nylock. Run the bolt from the inside out, hold with an allen, slip a washer on the outside and screw on the nylock. A small socket fits inside the outside hole, and it tightens right up. I then just dap some rtv over the outside.

mark c
http://www.hydrotoys.com
02 GP1200R
96 XP
01 FZ-1
00 Sportsman 500
02 Bombbardier DS650 Baja
04 SXR 800

Thanks guys.

John

99XL1200R
My Setup

"Harmonics my behind"...t sure sounds pretty

Over 100 hours with JB weld and still in place. Renicked with JB weld and still in place. Mother in law went two Asia twice and JB weld still in place.

You can also use Belzona if you can find it. Its also stronger than JB and harmonic proof!!
Fernando

my grandfather once used JB weld for a similar type of application, it lasted on year in a 1984 buick...lol, then it was drill it and tap it for a plug...i know becasue it was i who had to pull everything away to drill and tap because the local garage wanted 500 bucks to do it.

it could get ugly if small pieces of that stuff broke off and found its way into the valve stem area...jmo

i guess if your jb weld is holding up then my paper thin cylinders should hold as well, ill keep my fingers crossed... for both of us!

quote:

---

Originally posted by Mark C.:
allen head bolt, and nylock. Run the bolt from the inside out, hold with an allen, slip a washer on the outside and screw on the nylock
04 SXR 800

---

Great idea without touching the juggs and full proof!

quote:

---

Originally posted by Mark C.:
What I did to preserve the holes, yet prevent failure was use allen head bolt, and nylock. Run the bolt from the inside out, hold with an allen, slip a washer on the outside and screw on the nylock. A small socket fits inside the outside hole, and it tightens right up. I then just dap some rtv over the outside.

mark c

---

Mark,
Do you remember the sizes of the bolts, washer and nylocks you used? Great Idea.

John

99XL1200R
My Setup

Okay, I think they are a size M6 and about an inch long. Here is a pic. Does this help?


mark c
http://www.hydrotoys.com
02 GP1200R
01 FZ-1
00 Sportsman 500
04 SXR 800

[This message was edited by Mark C. on Fri February 27 2004 at 11:06 AM.]